Stator assembly with an overmolding that secures magnets to a flux ring and the flux ring to a stator housing

ABSTRACT

A stator assembly for an electric motor includes a stator housing, an expandable flux ring inserted into the stator housing and a plurality of magnets on an inner surface of the flux ring. Overmold material is molded around the magnets in the flux ring, such as by injection molding. The pressure of the overmold material as it is being molded expands the flux ring pressing the flux ring into engagement with the stator housing. The overmold material secures the magnets to the flux ring and the flux ring to the housing. One of the flux ring and stator housing has a dimple that engages a hole in the other of the flux ring and stator housing to align the flux ring and stator housing. In an aspect, the overmold material is molded to form at least one of a commutator end or rear bearing support, front bearing support and fan baffle. In an aspect, the overmold material is molded to form a keying feature. The keying feature can be slots of different widths between magnetic poles of the stator assembly. In an aspect, the flux ring and housing are preformed as a unit by stamping them from blanks and rolling them together. In a variation, the flux ring blank is rolled first to form the flux ring and the housing blank rolled around the flux ring with the flux ring acting as a rolling arbor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 10/468,643 filed Aug. 20, 2003, which is a § 371 National Phasefiling of PCT International Application PCT/US02/05029 filed Feb. 22,2002 (International Publication Number WO 02/068235 A2) which claims thebenefit of U.S. Provisional Application No. 60/271,141 filed Feb. 23,2001. This application claims the benefit of U.S. ProvisionalApplication No. 60/433,496 filed Dec. 13, 2002. The disclosures of theabove applications are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to electric motors, and more particularlyto stator assemblies for electric motors.

BACKGROUND OF THE INVENTION

In the construction of stator assemblies for permanent magnet electricmotors, magnets are retained within the stator assembly. For example, ina brush-type permanent magnet electric motor, magnets are retained on astator housing or a separate flux ring within the stator housing. Thisgenerally requires gluing or adhering each individual magnet to the fluxring or stator housing.

Various types of adhesives have been used to adhere the magnets to themetallic surface. It is possible that a sudden shock to the electricmotor will destroy the bond between the magnet and the flux ring orstator housing. This would result in movement of the magnet within thestator assembly. The magnet itself could even break. As a result, theelectric motor ceases to properly function.

It is known in the art to provide an anchor in the flux ring or statorhousing. Magnetic material is then injection molded on the flux ring orstator housing and is retained in position by the anchor. Such an anchorsystem is disclosed in U.S. Pat. No. 6,522,042 issued Feb. 18, 2003entitled Anchoring System for Injection Molded Magnets on a Flux Ring orMotor Housing and in U.S. application Ser. No. 09/764,004 filed Jan. 17,2001 entitled Anchoring System for Injection Molded Magnets on a FluxRing or Motor Housing. However, a disadvantage of the anchoring systemsdescribed in the above-identified patent applications is that theyrequire the use of injection molded magnetic material. This is typicallythe most expensive type of magnetic material per unit flux.

SUMMARY OF THE INVENTION

Accordingly, the present invention provides a stator assembly for anelectric motor. The stator assembly includes a stator housing, a splitflux ring inserted into the stator housing and a plurality of magnets onan inner surface of the flux ring. An overmolding secures the magnets tothe flux ring and asserts a radial force on the flux ring to secure itto the stator housing. Additionally, the overmolding fills the seam ofthe flux ring and prevents collapse of the flux ring.

In an aspect of the invention, the material used to mold the overmoldingis a plastic that is injection molded about the magnets on the flux ringafter the flux ring and magnets have been placed in the stator housing.The pressure of the plastic as it is being injection molded exerts aradial pressure on the flux ring, expanding it against the statorhousing and secures it to the stator housing. The overmolding alsosecures the magnets to the flux ring.

In an aspect of the invention, the flux ring is aligned with the statorhousing and is further secured to it by engagement of a dimple in one ofthe flux ring and stator housing with a hole in the other of the fluxring and the stator housing.

In an aspect of the invention, at least one of a rear bearing support,front bearing support and fan baffle are integrally molded with theovermolding when the material used to mold the overmolding is molded.

In an aspect of the invention, the overmolding is formed with slots ofdifferent widths between magnetic poles of the stator assembly toprovide a keying feature for the stator assembly to key it, such as whenit is placed in a magnetizer.

In an aspect of the invention, the flux ring and housing are preformedas a unit by stamping them from blanks and rolling them together. In avariation, the flux ring blank is rolled first to form the flux ring andthe housing blank rolled around the flux ring with the flux ring actingas a rolling arbor.

In an aspect of the invention, an electric motor has an armature and astator assembly in accordance with the invention.

In an aspect of the invention, a power tool has a housing including anelectric motor having an output coupled to a transmission. The electricmotor has an armature and a stator assembly in accordance with theinvention.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a cross-sectional view of a power tool according to thepresent invention;

FIG. 2 is a perspective view of a stator assembly of the power tool ofFIG. 1;

FIG. 3 is a cross-section view of the stator assembly of FIG. 2 takenalong the line 3—3;

FIG. 4 is a perspective view of a flux ring of the stator assembly ofFIG. 2;

FIG. 5 is a perspective view of a stator can or housing of the statorassembly of FIG. 2;

FIG. 6 is a perspective view of the flux ring of FIG. 4 received in thestator can of FIG. 5;

FIG. 7 is a perspective view of a variation of the flux ring of FIG. 4showing a flux ring with interlocking fingers;

FIG. 8 is a cross-sectional view of an alternative configuration of thestator assembly of FIG. 2;

FIG. 9 is a perspective view of an electric motor having an alternativeconfiguration of the stator assembly of FIG. 2;

FIG. 10 is a cross-sectional view of the electric motor of FIG. 9 takenalong the line 10—10;

FIG. 11 is a perspective view of an alternative stator assembly; and

FIG. 12 is a perspective view of still another alternative statorassembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiments is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

Referring now to FIG. 1, a power tool 10 is shown. The power tool 10 isillustrated as a drill, however, any type of power tool may be used inaccordance with the present invention. The power tool 10 includes ahousing 12 which surrounds a motor 14. An activation member 16 iscoupled with the motor and a power source 18. The power source 18includes either a power cord (AC current) or includes a battery (DCcurrent) (not shown). The motor 14 is coupled with an output 20 thatincludes a transmission 22 and a chuck 24. The chuck 24 is operable toretain a tool (not shown).

The motor includes a stator assembly 30. The stator assembly 30 includesa stator housing 32, a flux ring 34 and magnets 36. The flux ring 34 isan expandable or split flux ring. An armature 40 includes a shaft 42, arotor 44 and a commutator 50 coupled with the shaft 42. The rotor 44includes laminations 46 and windings 48. The motor 14 also includes endplates 52 and 54. End plate 52 includes a front bearing 56 whichsupports one end of a shaft 42. The shaft 42 is coupled with a pinion 60that is part of the output 20. Brushes 62 and 64 are associated with thecommutator 50. A rear bearing 70 is also coupled with the end plate 54to balance rotation of the shaft 42.

Referring now to FIGS. 2-6, the stator assembly 30 is described infurther detail. Stator housing 32 and flux ring 34 are illustrativelymade of soft magnetic material, such as cold rolled steel. The flux ring34 has anchors 80 extending radially inward. The magnets 36 are disposedaround an inner surface 82 of the flux ring 34 between anchors 80. Anovermolding 84 secures the magnets 36 to flux ring 34 as described inmore detail in WO 02/068235 A2.

The flux ring 34 is discontinuous having a seam 86 extending therealong.The seam 86 enables the flux ring 34 to be compressed for insertion intothe stator housing 32. When flux ring 34 is assembled in stator assembly30, the seam 86 is preferably disposed over one of magnetic poles P₁, P₂of the stator assembly 30 to minimize magnetic losses. In theconfiguration of FIGS. 2-6, the flux ring 34 includes a projection ordimple 88 that engages a hole 90 in the stator housing 32.Alternatively, as shown in FIG. 8, the stator housing 32 includes aprojection or dimple 92 that engages a hole 94 in the flux ring 34.Engagement of the dimple 88,92 and hole 90,94 provides proper alignmentof the flux ring 34 during assembly of the stator assembly 30. Thedimple 88,92 and hole 90,94 are illustratively at ninety degrees to seam86 to provide sufficient displacement of dimple 88 or hole 94, asapplicable, in flux ring 34 with respect to stator housing 32 when fluxring 34 is compressed so that when flux ring 34 is uncompressed, dimple88 will be urged into hole 90 (or hole 94 around dimple 92).Alternatively, the dimple 88, 92 and hole 90, 94 are ideally centeredover one of the magnetic poles P₁, P₂ to reduce magnetic losses.Overmolding 84 is formed so there are slots 95, 96 on diametricallyopposite sides of flux ring 34 between the overmolding 84 around magnets36 of pole P₁, and the overmolding 84 around magnets 36 of pole P₂.Slots 95, 96 illustratively extend axially along inner surface 82 offlux ring 34 between poles P₁ and P₂. Slots 95, 96 may be gaps in theovermolding 84 or regions of reduced thickness in the overmolding 84. Inthe illustrative embodiment, stator assembly 30 has one pair of magneticpoles, with one of poles P₁ and P₂ thus being a North pole and the otherbeing a South pole. It should be understood that stator assembly 30could have more than one pair of North and South poles.

To assemble the stator assembly 30, stator housing 32 and flux ring 34are each preformed. In this regard, stator housing 32 illustratively hasinterlocking fingers 33 as shown in FIG. 5. The flux ring 34 is slightlycompressed and inserted into the stator housing 32 as shown in FIG. 6.The dimple 88,92 engages the hole 90,94 as described above. The magnets36 are placed against the inner surface 82 of the flux ring 34 and arepositioned between the anchors 80. The magnets 36 can be lightlymagnetized so they are retained against the inner surface 82 of fluxring 34 during assembly.

Overmold material 83, such as plastic, is injection molded into thestator assembly 30 to form the overmolding 84. During the injectionmolding process, the pressure of the overmold material 83 pushes againstthe magnets 36 and flux ring 34, expanding the flux ring 34 against thestator housing 32. The overmold material 83 fills the seam 86 of fluxring 34 and surrounds the magnets 36. Expansion of the flux ring 34against the stator housing 32 provides the retention force for retainingthe flux ring 34 within the stator housing 32. Further, because theovermolding 84 fills the seam 86 of the flux ring 34, compression of theflux ring 34 in the stator housing 32 is prevented after the overmoldmaterial 83 hardens, thus preventing the removal of flux ring 34 fromthe stator housing 32. The engagement of the dimple 88, 92 and hole 90,94, held in place by the overmolding 84, further secures the flux ring34 to the stator housing 32. The diameter and true position of theovermolding 84 are maintained closely relative to the inside diameter ofthe stator housing 32 to reduce tolerance stack-ups to the armature 40(FIG. 1). It should be understood that there can be more than onedimple/hole arrangement in flux ring 34 and stator housing 32.

In an aspect of the invention, slot 95 is wider than slot 96 (as shownin phantom in FIG. 3 with respect to slot 95). This limits to two theorientations in which stator assembly 30 can be placed in a magnetizer(not shown) used to magnetize magnets 36 after stator assembly 30 isassembled. That is, the difference in the widths of slots 95 and 96provide a keying feature that keys stator assembly 30 to the magnetizer.If the widths of slot 95 and 96 were the same, stator assembly 30 couldbe placed in the magnetizer in four orientations. That is, either end ofstator assembly 30 could be placed in the magnetizer in two orientationsthat are 180 degrees apart. By forming the keying feature in theovermolding 84, each end of the stator assembly 30 can be placed in themagnetizer in only one orientation, reducing to two the orientations inwhich the stator assembly 30 can be placed in the magnetizer. This makessensing of the stator assembly 30 in the magnetizer fixture more robustand eliminates the possibility of magnetizing backwards due to placingthe stator assembly 30 in the magnetizer in the wrong orientation. Itshould be understood that in stator assemblies having more than twopoles, preferably the width of only one of the slots between the poleswould be different than the widths of the rest of the slots between thepoles to key the stator assembly to the magnetizer.

In an aspect of the invention, the stator housing 32 and the flux ring34 are preassembled as a unit according to an alternative assemblymethod. More specifically, the stator housing 32 and flux ring 34 areformed of separate blanks, such as steel blanks, and in this regard, theedges of the seams of flux ring 34 and stator housing 32 are formed tohave interlocking fingers, such as interlocking fingers 33 shown in FIG.5 for stator housing 32 and interlocking fingers 37 shown in FIG. 7 forflux ring 34. One or more holes 94 are stamped into the flux ring andmatching mating dimple(s) 92 stamped in the stator housing 32, orvice-versa. The stator housing 32 and flux ring 34 are lain together intheir flat, pre-rolled states with the holes and dimples engaged. Thestator housing 32 and flux ring 34 are rolled and the seam of the fluxring 34 interlocks as does the seam of the stator housing 32. The holesand dimples maintain alignment of the stator housing 32 and flux ring 34during the rolling process.

In an alternative, the flux ring 34 can be rolled first and the statorhousing 32 rolled about the flux ring 34. In this case, the flux ring 34acts as a rolling arbor. Additionally, the holes and dimples maintainalignment as the stator housing 32 is rolled about the flux ring 34.According to another alternative, the stator housing 32 and flux ring 34can be spot-welded together to form a sub-assembly. Regardless of howthe stator housing 32 and flux ring 34 are assembled together, injectionof the overmold material 83 not only secures the magnets 36 to the fluxring 34 but also secures the flux ring 34 to the stator housing 32through the pressure exerted on the flux ring 34 therein.

The stator assembly 30 of the present invention provides significantadvantages in both assembly and manufacture of the power tool 10. Inparticular, the stator assembly 30 eliminates the need for weldingequipment to secure the components together. The expansion of flux ring34 against stator housing 32 induced by injection of the overmoldmaterial 83 secures the flux ring 34 to stator housing 32 and theovermolding 84 also secures the magnets to flux ring 34. Theinterlocking of the dimple/hole arrangement(s) further secure the fluxring 34 to the stator housing 32. Further, injection of the overmoldmaterial 83 reduces tolerance stack-ups, improving ease of assembly. Asa result, manufacturing equipment and floor space is reduced entailingcost savings. Another advantage of reduced tolerance stack-ups is thatthe magnet can be placed closer to the armature 40 thus maximizing motorperformance. The keying feature provided by the different widths ofslots 95, 96 improve the placement of stator assembly 30 in themagnetizer.

Turning now to FIGS. 9 and 10, an electric motor 98 having a furtherembodiment of the stator assembly 30, indicated generally by referencenumeral 100, is shown. The stator assembly 100 includes the statorhousing 32, flux ring 34, and permanent magnets 36 as shown in thestator assembly 30 of FIGS. 2-6. The stator assembly 100 furtherincludes an integrally molded commutator end or rear bearing support 102and an integrally molded fan baffle 104. An armature, such as armature40 (FIG. 1), is received in stator assembly 100. A fan 112 is affixed atone end of shaft 42 of armature 40 and is disposed within fan baffle104. An insulative sleeve 114 may illustratively be disposed betweenshaft 42 and laminations 46 and between shaft 42 and commutator 50. Anend plate (not shown in FIGS. 9 and 10), such as end plate 52 (FIG. 1),is affixed to fan baffle 104.

The rear bearing support 102 includes a cap 106 integrally molded fromthe overmold material 83. The cap 106 includes a pocket 108 forreceiving rear bearing 70 (FIG. 1). Integrally forming the cap 106 aspart of the overmolding 84 from the overmold material 83 eliminates theneed for separate fasteners to fix the rear bearing support 102 to thestator housing 32. The fan baffle 104 is likewise integrally molded fromthe overmold material 83.

Turning now to FIG. 11, an alternate embodiment of stator assembly 100is shown and generally indicated by reference numeral 100′. Statorassembly 100′ is substantially similar to the stator assembly 100 shownin FIGS. 9 and 10, however, only the rear bearing support 102 isintegrally molded as part of the overmolding 84 from the overmoldmaterial 83. Alternatively, a front bearing support 103 (shown inphantom in FIG. 11) for engaging a front bearing, such as bearing 56(FIG. 1), may be integrally molded in a manner substantially similar tothe rear bearing support 102.

With reference to FIG. 12, another alternate embodiment of statorassembly 100 is illustrated and generally indicated by reference numeral100″. Stator assembly 100″ is substantially similar to the statorassembly 100 shown in FIGS. 9 and 10, however, only the fan baffle 104is integrally molded as part of overmolding 84 from the overmoldmaterial 83.

By integrally molding the commutator end bearing support 102 and the fanbaffle 104 as part of overmolding 84, further assembly and costs savingsmay be realized.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the gist of the invention areintended to be within the scope of the invention. Such variations arenot to be regarded as a departure from the spirit and scope of theinvention.

1. A stator assembly, comprising: a housing; a flux ring disposed withinthe housing, the flux ring including anchors extending radially inward;a plurality of permanent magnets disposed around an inner surface of theflux ring between the anchors; and a material overmolded around theplurality of magnets and the anchors to secure the magnets to the fluxring and to secure the flux ring to the housing.
 2. A stator assembly,comprising: a housing; a flux ring disposed within the housing; aplurality of permanent magnets disposed around an inner surface of theflux ring; a material overmolded around the plurality of magnets tosecure the magnets to the flux ring and to secure the flux ring to thehousing; and the flux ring including a seam that allows the flux ring tobe compressed for insertion into the housing during assembly, theovermold material expanding the flux ring against the housing.
 3. Thestator assembly of claim 2 wherein the seam of the flux ring is filledwith the overmold material during molding of the overmold material, theovermold material upon hardening preventing the flux ring fromcompressing.
 4. The stator assembly of claim 2 wherein the statorassembly has a plurality of magnetic poles, the seam of the flux ringaligned with one of the magnetic poles.
 5. The stator assembly of claim2 wherein one of the flux ring and the housing includes at least oneprojection and the other of the flux ring and the housing includes atleast one hole, the projection being received in the hole to align theflux ring in the housing.
 6. The stator assembly of claim 5 wherein theprojection and hole of the flux ring and housing are disposed aboutninety degrees from the seam of the flux ring.
 7. The stator assembly ofclaim 2, further including at least one of a rear bearing support, frontbearing support and fan baffle integrally formed of the overmoldmaterial during molding of the overmold material.
 8. The stator assemblyof claim 2, further including a rear bearing support integrally formedof the overmold material during molding of the overmold material, therear bearing support including a cap having a pocket therein forreceiving a rear bearing.
 9. The stator assembly of claim 1, wherein theovermold material is a plastic.
 10. A stator assembly, comprising: ahousing; a flux ring disposed within the housing; a plurality ofpermanent magnets disposed around an inner surface of the flux ring; anda material overmolded around the plurality of magnets to secure themagnets to the flux ring and to secure the flux ring to the housingwherein at least one keying feature is formed in the overmold materialbetween magnetic poles of the stator assembly.
 11. The stator assemblyof claim 10 wherein the keying feature includes slots formed in theovermold material between the magnetic poles with widths of at least twoof the slots being different.
 12. The stator assembly of claim 1 whereinthe plurality of magnets includes four magnets, the stator assemblyhaving a first magnetic pole defined by two of the magnets that areadjacent to each other and a second magnetic pole defined by the othertwo of the magnets that are adjacent to each other, the overmoldmaterial molded to have a first slot between the magnets of the firstand second magnetic poles on a first side of the flux ring and a secondslot between the magnets of the first and second magnetic poles on asecond side of the flux ring that is diametrically opposed to the firstside of the flux ring, the first and second slots having differentwidths.
 13. A stator assembly comprising: a housing; a flux ringdisposed within the housing, the flux ring having a seam that allows theflux ring to be compressed for insertion into the housing duringassembly; a plurality of permanent magnets disposed around an innersurface of the flux ring, each magnet disposed between at least twoanchors extending radially inwardly from an inner surface of the fluxring; and a material overmolded around the plurality of magnets and theanchors to secure the magnets to the flux ring, to secure the flux ringto the housing by expanding the flux ring against the housing and toprevent the flux ring from compressing by filling the seam of the fluxring.
 14. The stator assembly of claim 13 wherein one of the flux ringand the housing includes at least one projection and the other of theflux ring and the housing includes at least one hole in which the atleast one projection is received, the seam of the flux ring aligned witha first magnetic pole of the stator assembly.
 15. The stator assembly ofclaim 14 wherein the projection and hole of the flux ring and housingdisposed about ninety degrees from the seam of the flux ring.
 16. Thestator assembly of claim 14 wherein the projection and hole of the fluxring and housing are aligned with a second magnetic pole of the statorassembly.
 17. The stator assembly of claim 13 wherein at least onekeying feature is formed in the overmold material between magnetic polesof the stator assembly, the keying feature including slots formed in theovermold material between magnetic poles of the stator assembly when theovermold material is molded with widths of at least two of the slotsbeing different.
 18. A power tool comprising: a housing; a motordisposed within the housing and having an output coupled to atransmission, the motor having a stator assembly having a flux ringdisposed within a stator housing with a plurality of permanent magnetsdisposed around an inner surface of the flux ring, the flux ringincluding anchors extending radially inward with each of the pluralityof permanent magnets disposed between at least two of the anchors, and amaterial overmolded around the plurality of magnets and the anchors tosecure the magnets to the flux ring and secure the flux ring to thestator housing.
 19. A power tool comprising: a housing; and a motordisposed within the housing and having an output coupled to atransmission, the motor having a stator assembly having a flux ringdisposed within a stator housing, a plurality of permanent magnetsdisposed around an inner surface of the flux ring, and a materialovermolded around the plurality of magnets to secure the magnets to theflux ring and secure the flux ring to the stator housing, the flux ringincluding a seam that allows the flux ring to be compressed forinsertion into the housing during assembly of the stator assembly, theovermold material expanding the flux ring against the stator housing.20. The power tool of claim 19 wherein the seam of the flux ring isfilled with the overmold material that prevents the flux ring fromcompressing.
 21. The power tool of claim 19 wherein the seam is alignedwith a magnetic pole of the stator assembly.
 22. The power tool of claim19 wherein one of the flux ring and the housing includes at least oneprojection and the other of the flux ring and the housing includes atleast one hole in which the projection is received to align the fluxring in the housing.
 23. The power tool of claim 22 wherein theprojection and hole of the flux ring and housing are disposed aboutninety degrees from the seam of the flux ring.
 24. The power tool ofclaim 22 wherein the stator assembly includes at least one of a rearbearing holder, front bearing holder and fan baffle integrally formed ofthe overmold material during molding of the overmold material.
 25. Thepower tool of claim 22 wherein the overmold material is a plastic.
 26. Apower tool comprising: a housing; and a motor disposed within thehousing and having an output coupled to a transmission, the motor havinga stator assembly having a flux ring disposed within a stator housing, aplurality of permanent magnets disposed around an inner surface of theflux ring, and a material overmolded around the plurality of magnets tosecure the magnets to the flux ring and secure the flux ring to thestator housing, and at least one keying feature formed in the overmoldmaterial between magnetic poles of the stator assembly, the keyingfeature including slots formed in the overmold material between themagnetic poles when the overmold material is molded with widths of atleast two of the slots being different.
 27. The stator assembly of claim1 further including at least one of a rear bearing support, frontbearing support and fan baffle integrally formed of the overmoldmaterial during molding of the overmold material.
 28. The statorassembly of claim 1 further including a rear bearing support integrallyformed of the overmold material during molding of the overmold material,the rear bearing support including a cap having a pocket therein forreceiving a rear bearing.
 29. The stator assembly of claim 1 wherein theovermold material is plastic.
 30. The power tool of claim 18, whereinthe stator assembly includes at least one of a rear bearing holder,front bearing holder and fan baffle integrally formed of the overmoldmaterial during molding of the overmold material.
 31. The power tool ofclaim 18, wherein the overmold material is a plastic.